Gradient printing a three-dimensional structural component

ABSTRACT

Methods are provided for printing a three-dimensional structural component onto a base. For example, a method of printing is provided, including receiving a set of predetermined thicknesses for the three-dimensional structural component. The set of predetermined thicknesses has a first thickness and a second thickness. The first thickness is greater than the second thickness. The method further includes instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses. The method further includes printing a first portion of the single layer onto the base so that the first portion has the first thickness. The method further includes printing a second portion of the single layer onto the base so that the second portion has the second thickness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/343,757, filed May 31, 2016, which is incorporatedherein by reference in its entirety.

BACKGROUND

Embodiments relate generally to printing UV-curable graphic layers onbases such as the fabric used to make articles of apparel such asshirts, shorts, pants, jackets, hats or caps, or to make uppers forarticles of footwear, such as running, training, jogging, hiking,walking, volleyball, handball, tennis, lacrosse, basketball shoes, andother similar articles of footwear, as well as to make other articlessuch as backpacks or tents.

Articles of apparel may be made of a woven or nonwoven fabric, or of amesh material, or may be made of leather, synthetic leather, or ofplastic materials. Articles of apparel may have items such as emblems orlogos on the sleeves, torso, pants leg, or other portions of the articleof apparel. Articles of apparel may also have abrasion-resistant,water-resistant or protective layers at, for example, the elbows, theshoulders, and/or the knees.

Printers or plotters may be programmed to deposit layers of acrylicresin ink, polyurethane ink, TPU ink or silicone ink or other inks on afabric or other article. Such printers or plotters may be programmed tocover a two-dimensional portion of a fabric, for example, by moving aprinthead along a track in a first direction and moving the track in asecond direction that is orthogonal to the first direction. Otherprinters or plotters may move the printhead in a first direction whilemoving the printer platform in a second direction that is orthogonal tothe first direction, or may move the platform in both directions whilekeeping the printhead stationary.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 shows a schematic diagram of a printing system, in accordancewith an exemplary embodiment;

FIG. 2 shows a perspective view of a portion of a printing device, inaccordance with an exemplary embodiment;

FIG. 3 shows a block diagram of a process for printing athree-dimensional structural component with a single layer havingvarying thicknesses, in accordance with an exemplary embodiment;

FIG. 4 shows a schematic diagram of the printing system of FIG. 1receiving a base, in accordance with an exemplary embodiment;

FIG. 5 shows a schematic diagram of the printing system of FIG. 4receiving a set of predetermined thicknesses, in accordance with anexemplary embodiment;

FIG. 6 shows a schematic view of dispensing a print material onto thebase of FIG. 4 to form a first portion of a single layer, in accordancewith an exemplary embodiment;

FIG. 7 shows a schematic view of dispensing a print material onto thebase of FIG. 4 to form a second portion of the single layer, inaccordance with an exemplary embodiment;

FIG. 8 shows a schematic view of dispensing a print material onto thebase of FIG. 4 to form a third portion of a single layer, in accordancewith an exemplary embodiment;

FIG. 9 shows an exemplary single layer of a three-dimensional structuralcomponent printed onto the base of FIG. 4, in accordance with anexemplary embodiment;

FIG. 10 shows a block diagram of a process for printing athree-dimensional structural component with multiple layers, inaccordance with an exemplary embodiment;

FIG. 11 shows a schematic diagram of the printing system of FIG. 1receiving a base and receiving a set of predetermined thicknesses, inaccordance with an exemplary embodiment;

FIG. 12 shows a schematic view of dispensing a print material onto thebase of FIG. 11 to form a first layer, in accordance with an exemplaryembodiment;

FIG. 13 shows the first layer of FIG. 12, in accordance with anexemplary embodiment;

FIG. 14 shows positioning a printhead assembly of the printing systemfor printing a second layer onto the first layer of FIG. 12, inaccordance with an exemplary embodiment;

FIG. 15 shows a schematic view of dispensing a print material onto thefirst layer of FIG. 12 to form a second layer, in accordance with anexemplary embodiment;

FIG. 16 shows the second layer of FIG. 15, in accordance with anexemplary embodiment;

FIG. 17 shows a block diagram of a process for printing athree-dimensional structural component with multiple layers for forminga three-dimensional structural component having a smooth slope, inaccordance with an exemplary embodiment;

FIG. 18 shows a schematic diagram of the printing system of FIG. 1receiving a base and receiving a set of predetermined thicknesses, inaccordance with an exemplary embodiment;

FIG. 19 shows a schematic view of dispensing a print material onto thebase of FIG. 18 to form a first layer, in accordance with an exemplaryembodiment;

FIG. 20 shows the first layer of FIG. 19 and positioning a printheadassembly of the printing system for printing a second layer onto thefirst layer of FIG. 19, in accordance with an exemplary embodiment;

FIG. 21 shows a schematic view of dispensing a print material onto thefirst layer of FIG. 19 to form a second layer, in accordance with anexemplary embodiment;

FIG. 22 shows the second layer of FIG. 21, in accordance with anexemplary embodiment;

FIG. 23 shows a table correlating spot color and thickness;

FIG. 24 is an enlarged schematic view of a set of layers printed using aset of spot color percentages, according to an embodiment;

FIG. 25 is a schematic view of a set of layers printed using a set ofspot color percentages, according to an embodiment;

FIG. 26 is a schematic view of a process for generating and using acorrected spot color table for printing; and

FIG. 27 is a schematic view of a table showing adjusted spot colorpercentages used to obtain desired target thicknesses.

DETAILED DESCRIPTION

For clarity, the detailed descriptions herein describe certain exemplaryembodiments, but the disclosure in this application may be applied toany method for fabricating an article including any suitable combinationof features described herein and recited in the claims. In particular,although the following detailed description describes certain exemplaryembodiments, it should be understood that other embodiments may be usedfor the fabrication of other articles of footwear or apparel.

As used herein, the terms “printing device,” “printer,” “plotter,” “3Dprinter,” “three-dimensional printing system,” or “3D printing system”may refer to any type of system that can print multiple layers onto afabric, an article of footwear, an article of apparel or other article,including, for example, sign and graphics printers. The printers may useany appropriate type of UV-curable ink, including acrylic resin ink,polyurethane ink, TPU ink or silicone ink or any other appropriate ink.

In one aspect, a method of printing a three-dimensional structuralcomponent onto a base is provided. The method includes receiving a setof predetermined thicknesses for the three-dimensional structuralcomponent. The set of predetermined thicknesses has a first thicknessand a second thickness. The first thickness is greater than the secondthickness. The method includes instructing a printing device to print asingle layer for the three-dimensional structural component using theset of predetermined thicknesses. The method includes printing a firstportion of the single layer onto the base so that the first portion hasthe first thickness. The method includes printing a second portion ofthe single layer onto the base so that the second portion has the secondthickness.

In another aspect, a method of printing a three-dimensional structuralcomponent onto a base is provided. The method includes receiving a setof predetermined thicknesses for the three-dimensional structuralcomponent. The set of predetermined thicknesses has a first thicknesscorresponding to a first position of the base and a second thicknesscorresponding to a second position of the base. The first thickness isgreater than the second thickness. The method includes instructing aprinting device to print a set of layers of the three-dimensionalstructural component using the set of predetermined thicknesses. The setof layers includes at least a first layer and a second layer. The methodincludes printing the first layer of the three-dimensional structuralcomponent directly onto the base using the set of predeterminedthicknesses. Printing the first layer includes printing the first layerto have the first thickness at the first position of the base. Printingthe first layer includes printing the first layer to have the secondthickness at the second position of the base. The method includesprinting the second layer of the three-dimensional structural componentdirectly onto the first layer using the set of predeterminedthicknesses. Printing the second layer includes printing the secondlayer to have the first thickness at the first position of the base.Printing the second layer includes printing the second layer to have thesecond thickness at the second position of the base.

In another aspect, a method of printing a three-dimensional structuralcomponent onto a base is provided. The method includes receiving a setof predetermined thicknesses for the three-dimensional structuralcomponent. The method includes instructing a printing device to print aset of layers of the three-dimensional structural component onto thebase. The method includes printing the three-dimensional structuralcomponent onto the base using the set of predetermined thicknesses toform a printed set of layers. Printing the three-dimensional structuralcomponent includes printing a first layer of the set of layers directlyonto the base. A separation distance between the base and a printheadassembly of the printing device remains constant during the step ofprinting the first layer of the set of layers directly onto the base.The printed set of layers includes an exposed surface of thethree-dimensional structural component. The exposed surface includes atall region, an intermediate region, and a short region. Theintermediate region abuts the tall region. The intermediate region abutsthe short region. A difference in height between the tall region of theexposed surface and the short region of the exposed surface is greaterthan the separation distance. The intermediate region of the exposedsurface has a smoothly sloped geometry.

Other systems, methods, features, and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description and this summary bewithin the scope of the embodiments.

Although the drawings and the textual description herein only describeembodiments as they may be used on certain articles of footwear orcertain articles of apparel, the descriptions herein may also be appliedto other articles of footwear and/or to other articles of apparel,including, for example, articles of footwear such as running, training,jogging, hiking, walking, volleyball, handball, tennis, lacrosse,basketball shoes and other similar articles of footwear, or articles ofapparel such as shorts, shirts, jerseys, jackets, pants, gloves, wristbands, headbands, armbands, hats or caps, as well as to other articlessuch as backpacks or tents.

FIG. 1 is a schematic view of an embodiment of three-dimensionalprinting system 100, also referred to simply as printing system 100.Some embodiments of the printing system can include provisions thatdistribute one or more functions among different devices of the printingsystem. As shown, printing system 100 may include printing device 102,computing system 104, and network 106. In other embodiments, theprinting system may be a single device or component (not shown).

Some embodiments of the printing device can include provisions thatpermit color printing. In some embodiments, the printing system may useCMYK printing. In other embodiments, the color printing may be conductedusing another suitable printing method.

In embodiments where color printing is conducted using CMYK printing,any suitable device, protocol, standard, and method may be used tofacilitate the color printing. As used herein, “CMYK” may refer to fourpigments used in color printing: “C” for a cyan pigment, “M” for amagenta pigment, “Y” for a yellow pigment, and “K” for a key pigment. Insome cases, the key pigment may be a black pigment. An example of aprinting device using CMYK printing is disclosed in Miller, U.S. PatentPublication Number 2015-0002567, published on Jan. 1, 2015, titled“Additive Color Printing” (U.S. patent application Ser. No. 13/927,551,filed on Jun. 26, 2013), which application is herein incorporated byreference and referred to hereafter as the “Color Printing” application.In some embodiments, printing system 100 can include one or morefeatures of the systems, components, devices, and methods disclosed inthe Color Printing application to facilitate color printing. Forexample, the printing device may be configured to print an image bydispensing droplets of a print material including one or more pigmentsonto a base. As used herein, droplets may refer to any suitable volumeof print material. For example, a droplet may be 1 milliliter of printmaterial. In other embodiments, the printing system may use othersystems, components, devices, and methods.

In embodiments where the printing system includes provisions thatdistribute one or more functions among different devices of the printingsystem, any suitable division may be used. In some embodiments, printingsystem 100 can include provisions that control and/or receiveinformation from printing device 102. These provisions can includecomputing system 104 and network 106. Generally, the term “computingsystem” refers to the computing resources of a single computer, aportion of the computing resources of a single computer, and/or two ormore computers in communication with one another. Any of these resourcescan be operated by one or more human users. In some embodiments,computing system 104 may include one or more servers. In someembodiments, a print server may be primarily responsible for controllingand/or communicating with printing device 102, while a separate computer(e.g., desktop, laptop, or tablet) may facilitate interactions with auser. Computing system 104 can also include one or more storage devicesincluding, but not limited to, magnetic, optical, magneto-optical,and/or memory, including volatile memory and non-volatile memory.

In some embodiments, any suitable hardware or hardware systems may beused to facilitate provisions that control and/or receive informationfrom printing device 102. In some embodiments, where a computing systemis used, computing system 104 may include central processing device 185,viewing interface 186 (e.g., a monitor or screen), input devices 187(e.g., keyboard and mouse), and software for creating set ofpredetermined thicknesses 189 for printing a three-dimensionalstructural component. As used herein, a set of predetermined thicknessesmay include any suitable information to facilitate formation of athree-dimensional structural component to have a shape represented bythe set of predetermined thicknesses. Examples of shapes represented bya set of predetermined thicknesses may include cylinder, cone, cube,sphere, and the like. In some instances, the set of predeterminedthicknesses may be personalized for a particular customer. In otherembodiments, other forms of hardware systems may be used.

Generally, any suitable information may be used to facilitate provisionsfor software for designing a set of predetermined thicknesses for athree-dimensional structural component. In at least some embodiments,software for designing a set of predetermined thicknesses of a printedstructure may include not only information about the geometry of thestructure but also information related to the materials required toprint various portions of the component. In other embodiments, differentinformation may be used.

Generally any suitable design structure may be used to transform thedesign into information that can be interpreted by printing device 102(or a related print server in communication with printing device 102).In some embodiments, printing system 100 may be operated as follows toprovide one or more components that have been formed using athree-dimensional printing, or additive process. Computing system 104may be used to design a structure. This may be accomplished using sometype of CAD software or other kind of software. The design may then betransformed into information that can be interpreted by printing device102 (or a related print server in communication with printing device102). In some embodiments, the design may be converted to athree-dimensional printable file, such as a stereolithography file (STLfile); in other cases, the design may be converted into a differentdesign component.

In some embodiments where the printing system includes provisions thatdistribute one or more functions among different devices of printingsystem 100, any suitable protocol, format, and method may be used tofacilitate communication among the devices of printing system 100. Insome embodiments, these communications are conducted using network 106.In other cases, these communications may be conducted directly betweendevices of printing system 100.

In some embodiments, the network may use any wired or wirelessprovisions that facilitate the exchange of information between computingsystem 104 and printing device 102. In some embodiments, network 106 mayfurther include various components such as network interfacecontrollers, repeaters, hubs, bridges, switches, routers, modems, andfirewalls. In some embodiments, network 106 may be a wireless networkthat facilitates wireless communication between two or more systems,devices, and/or components of printing system 100. Examples of wirelessnetworks include, but are not limited to, wireless personal areanetworks (including, for example, BLUETOOTH), wireless local areanetworks (including networks utilizing the IEEE 802.11 WLAN standards),wireless mesh networks, mobile device networks as well as other kinds ofwireless networks. In other cases, network 106 could be a wired networkincluding networks whose signals are facilitated by twister pair wires,coaxial cables, and optical fibers. In still other cases, a combinationof wired and wireless networks and/or connections could be used.

Some embodiments of the printing system can include provisions thatpermit printed structures to be printed directly onto one or morearticles. The term “articles” is intended to include both articles offootwear (e.g., shoes) and articles of apparel (e.g., shirts, pants,etc.). As used throughout this disclosure, the terms “article offootwear” and “footwear” include any footwear and any materialsassociated with footwear, including an upper, and may also be applied toa variety of athletic footwear types, including baseball shoes,basketball shoes, cross-training shoes, cycling shoes, football shoes,tennis shoes, soccer shoes, and hiking boots. As used herein, the terms“article of footwear” and “footwear” also include footwear types thatare generally considered to be nonathletic, formal, or decorative,including dress shoes, loafers, sandals, slippers, boat shoes, and workboots.

While the disclosed embodiments are described in the context of articlesof footwear, various embodiments may further be equally applied to anyarticle of clothing, apparel, or equipment that includesthree-dimensional printing. For example, various embodiments may beapplied to hats, caps, shirts, jerseys, jackets, socks, shorts, pants,undergarments, athletic support garments, gloves, wrist/arm bands,sleeves, headbands, any knit material, any woven material, any nonwovenmaterial, sports equipment, etc. Thus, as used herein, the term “articleof apparel” may refer to any apparel or clothing, including any articleof footwear, as well as hats, caps, shirts, jerseys, jackets, socks,shorts, pants, undergarments, athletic support garments, gloves,wrist/arm bands, sleeves, headbands, any knit material, any wovenmaterial, any nonwoven material, and the like.

Referring to FIG. 1, which shows an embodiment including set of articles130, in other embodiments, different articles may be used. As shown, setof articles 130 includes article of footwear 132, shin guard 134, andarticle of apparel 136. In other embodiments, set of articles 130 may bedifferent.

Generally, any suitable surface of the article may be used as a base toreceive the three-dimensional objects. In some embodiments, the articleincludes a surface in a flattened configuration. Referring to FIG. 1,shin guard 134 may have a front surface and/or a back surface in aflattened configuration. In another example, article of apparel 136 mayhave a front surface and/or a back surface in a flattened configuration.In other embodiments, an article may include a surface having athree-dimensional configuration. For example, a side surface of articleof footwear 132 may have a three-dimensional configuration. In anotherexample, a top surface of shin guard 134 may have a three-dimensionalconfiguration. In other embodiments, the printing device and/or printingsystem may print onto other surfaces.

Some embodiments of the printing system can include provisions thatpermit printing directly onto the article. In other cases, thethree-dimensional structural component is first printed onto a releaselayer and then transferred onto the article.

In some embodiments any suitable material may be used to form thearticle to facilitate use of the article. In some embodiments, printingdevice 102 may be capable of printing onto the surfaces of variousmaterials such as a textile, natural fabric, synthetic fabric, knit,woven material, nonwoven material, mesh, leather, synthetic leather,polymer, rubber, and foam, or any combination of them, without the needfor a release layer interposed between a base and the bottom of theprint material, and without the need for a perfectly or near perfectlyflat base surface on which to print.

In some embodiments, the articles may be customizable. As used herein, acustomizable article may be preprocessed and unfinished. Referring toFIG. 1, the processing of article of footwear 132 may include cutting anupper in a particular shape and/or treating the upper to improvedurability for use as footwear. In some examples, the upper may befolded and attached to a sole. In other examples, the upper may be in aflat configuration (see FIG. 2). In the example of FIG. 1, article offootwear 132 may not be finished with a mass production design. Instead,article of footwear 132 may be suitable for finishing with apersonalized three-dimensional structural component for a particularcustomer.

Some embodiments of the printing device may include provisions thatpermit the printhead assembly to be moved across the base to facilitateprinting of features, such as images, graphics, designs, and text ontothe base. In some embodiments, the printing device may move theprinthead assembly along the base. In other embodiments, the printingdevice may move the base in relation to the printhead assembly.

In embodiments where the printing device moves the printhead assembly,the printing device may move the printhead assembly in a directionparallel to any suitable number of axes. In some embodiments, theprinting device may move the printhead assembly along a printingsurface. Referring to FIG. 1, printing device 102 may move printheadassembly 140 along base 160 to facilitate a printing onto base 160. Inthe example, printing device 102 may move printhead assembly 140parallel to first axis 156 and/or parallel to second axis 158. As shown,first axis 156 may extend parallel to base 160 and/or perpendicular tosecond axis 158. In the example, second axis 158 may extend parallel tobase 160 and/or perpendicular to first axis 156. In some embodiments,the printing device may raise or lower the printhead assembly. Referringto FIG. 1, printing device 102 may raise or lower printhead assembly 140along third axis 154. As shown, third axis 154 may be normal to base 160and perpendicular to first axis 156 and/or second axis 158. In otherembodiments, the printing device may move the printhead assemblyrelative to the base differently.

In embodiments where the printing device moves the base, the printingdevice may move the base in a direction parallel to any suitable numberof axes. In some embodiments, the printing device may move the basehorizontally with the printhead assembly. Referring to FIG. 1, printingdevice 102 may move base 160 parallel to first axis 156 and/or parallelto second axis 158. In some embodiments, the printing device may movethe base vertically with the printhead assembly. Referring to FIG. 1,printing device 102 may raise or lower base 160 relative to printheadassembly 140 in a direction parallel with third axis 154. In otherembodiments, the printing device may move the base relative to theprinthead assembly differently.

In some embodiments, the printhead assembly may be moved along acontinuous printing path to facilitate printing a single layer onto theentire surface of the base. Referring to FIG. 2, printing device 102 mayprint along continuous printing path 202. In the example, printheadassembly 140 may initially be positioned at left edge 210 of base 160and at top edge 214 of base 160. In the example, printhead assembly 140may be moved relative to base along one direction (e.g., right) ofsecond axis 158 until the printhead assembly 140 is positioned at rightedge 212. In the example, printhead assembly 140 may subsequently bemoved relative to base along one direction (e.g., down) of first axis156 toward bottom edge 216 of base 160 and then moved relative to base160 along the other direction (e.g., left) of second axis 158 until theprinthead assembly 140 is positioned at left edge 210. In this manner,printhead assembly 140 may continuously dispense print material onto anentire upper surface of base 160. In other embodiments, the printheadmay be moved along the base differently to facilitate printing on theentire surface of the base.

Some embodiments of the printing device may include provisions thatpermit the printhead assembly to print in both directions along an axisto facilitate printing along a continuous printing path. In someembodiments, the printhead assembly may include a curing device forprinting along one direction (e.g., right) parallel to an axis and acuring device for printing along the other direction (e.g., left)parallel to an axis. Referring to FIG. 2, printhead assembly 140 mayinclude curing device 220, which may emit ultraviolet light 224 asprinthead assembly moves along one direction (e.g., right) parallel tosecond axis 158. In the example, printhead assembly 140 may includecuring device 222, which may emit ultraviolet light 226 as printheadassembly moves along the other direction (e.g., left) parallel to secondaxis 158. In other embodiments, a single curing device may be used ormore than two curing devices may be used to facilitate printing along acontinuous printing path.

FIG. 3 shows a block diagram of a process for printing athree-dimensional structural component onto a base, in accordance withan exemplary embodiment. The various steps of FIG. 3 may be discussedwith respect to FIGS. 4-9. In some embodiments, the steps of FIG. 3 useCMYK printing. In some embodiments, the steps of FIG. 3 may use acontinuous printing path. In other cases, other methods, techniques,and/or processes may be used. In some embodiments, the steps of FIG. 3may be implemented using the system illustrated in FIG. 1. In othercases, other systems and/or devices may be used. It should be understoodthat additional and/or fewer steps may be used. The processesillustrated in FIGS. 4-9 are for illustrative purposes only.

In some embodiments, a base may be provided, as in step 302 (see FIG.3), to receive a three-dimensional structural component. In someembodiments, the base may be provided manually. Referring to FIG. 4, ahuman user may place base 410 onto platform 420 of printing device 102to permit printing device 102 to print directly onto base 410. As shown,the base may be an upper for an article of footwear. It should beunderstood that the base may be other articles as previously described.In other embodiments, the base may be provided automatically. Forexample, the placement of base 410 onto printing device 102 may beautomated using one or more loaders (not shown) to place base 410 (oranother substrate) onto printing device 102.

Some embodiments permit a customization of articles by facilitating aselection of a base from a set of bases. Referring to FIG. 4, a humanuser may select to print on first upper style 432, second upper style434, or third upper style 436 using input devices (e.g., keyboard andmouse) 187. In the example, first upper style 432 may have acorresponding first upper supply 402, second upper style 434 may have acorresponding first upper supply 404, and third upper style 436 may havea corresponding first upper supply 406. In the example, base 410 may beselected from first upper supply 402 according to the selection of firstupper style 432. In other embodiments, other methods may be used topermit a customization of articles.

In some embodiments, a set of predetermined thicknesses for athree-dimensional structural component may be provided, as in step 304(see FIG. 3). In some embodiments, the set of predetermined thicknessesmay be provided by a human user. Referring to FIG. 5, a human user, suchas a customer or designer, may generate set of predetermined thicknesses189 according to personal preferences using computing system 104. Itshould be understood that in some embodiments, at least a portion of theset of predetermined thicknesses may be automatically generated by acomputing device. In the example, computing system 104 may transmit setof predetermined thicknesses 189 to printing device 102, which may belocally connected to computing system 104 or may be remotely connectedto computing system 104 using network 106. In other embodiments, the setof predetermined thicknesses may be provided differently.

Generally, the set of predetermined thicknesses may have any suitablenumber of thicknesses to represent a shape of a three-dimensionalstructural component. In some embodiments, the set of predeterminedthicknesses may include two thicknesses. Referring to FIG. 5, set ofpredetermined thicknesses 189 may include first thickness 502 and secondthickness 504. As shown, first thickness 502 may be less than secondthickness 504. In other instances, second thickness may be less than orequal to first thickness (not shown). In some embodiments, the set ofpredetermined thicknesses may optionally include more than twothicknesses. Referring to FIG. 5, set of predetermined thicknesses 189may optionally include third thickness 506. In other embodiments, theset of predetermined thicknesses may have more than three thicknesses.

In some embodiments, the printing device may be instructed, as in step306 (see FIG. 3) to print a single layer for the three-dimensionalstructural component using the set of predetermined thicknesses. Theinstructions may be in any suitable format and/or use any suitabletopology. In some embodiments, the set of predetermined thicknesses maybe converted to a three-dimensional printable file, such as astereolithography file (STL file); in other cases, the set ofpredetermined thicknesses may be converted into a different designstructure. In some embodiments, a set of predetermined thicknesses mayuse a digital image or image file. For example, a set of predeterminedthicknesses may be an image file using a raster format, vector format,compound format, and/or stereo format. Examples of raster formats mayinclude joint photographic experts group (JPEG), tagged image fileformat (TIFF), graphics interchange format (GIF), bitmap image file(BMP), portable networks graphics (PNG), and the like. Examples ofvector formats may include computer graphics metafile (CGM), Gerberformat (GERBER), scalable vector graphics (SVG), and the like. Examplesof compound formats may include portable document format (PDF),encapsulated PostScript, PostScript, and the like. Examples of stereoformat may include JPEG stereo (JPS), portable networks graphics (PSN),and the like. It should be understood that some image files may supportmultiple layers such that multiple sets of predetermined thicknesses maybe stored in a single image file. In other embodiments, the instructionsmay be different.

In some embodiments, a first portion of a single layer for thethree-dimensional structural component may be printed, as in step 308(see FIG. 3), onto the base so that the first portion has the firstthickness. Referring to FIG. 6, printing device 102 may dispense printmaterial 602 in a liquid state onto base 410. In the example, curingdevice 220 may emit ultraviolet light 604 onto base 410 to cure firstportion 610 of single layer 620. In other embodiments, the first portionmay be printed differently.

In some embodiments, the printing device may move the printhead assemblyin a single pass for printing different portions of a single layer.Referring to FIG. 6-7, printing device 102 may move printhead assembly140 in single pass 630 between first portion 610 and second portion 720.In the example, the single pass may be from left edge 210 to right edge212. In other instances, the single pass may be from the right edge tothe left edge (not shown). In other embodiments, the printing device mayprint the first portion of the single layer using multiple passes (notshown).

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof moving the printhead assembly in the single pass. Referring to FIG.6, printing device 102 may move printhead assembly 140 parallel to uppersurface 636 such that separation distance 634 between upper surface 636and printhead assembly 140 remains constant during single pass 630. Inother embodiments, the separation distance may vary during the step ofmoving the printhead assembly in the single pass (not shown).

Generally, the separation distance between an upper surface of the baseand the printhead assembly may be any suitable distance. In someembodiments, the separation distance may be a predetermined printingparameter corresponding to the printing device. In some embodiments, theseparation distance may be a design parameter determined by a humanuser. For example, the separation distance may be a printing step sizeto achieve a desired surface profile. In some embodiments, theseparation distance may be automatically determined by software. Forexample, the separation distance may be a printing step size determinedaccording to a received surface profile.

In some embodiments, the printing device may print the first portion ofthe single layer during the single pass. In some embodiments, printingthe first portion of the single layer may include dispensing printmaterial in a liquid state from the printhead assembly onto the baseduring the single pass. Referring to FIG. 6, printhead assembly 140 maydispense print material 602 in a liquid state from printhead assembly140 onto base 410 during single pass 630. In some embodiments, printingthe first portion of the single layer may include curing the firstportion of the single layer during the single pass. Referring to FIG. 6,printhead assembly 140 may emit ultraviolet light 604 onto base 410 tocure first portion 610 of single layer 620 during single pass 630. Inother embodiments, the printing device may print the first portion ofthe single layer using additional and/or fewer steps.

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the first portion of the single layer. Referring to FIG. 6,printhead assembly 140 may dispense print material 602 using separationdistance 634 between upper surface 636 and printhead assembly 140. Inthe example, curing device 220 may emit ultraviolet light 604 onto base410 to cure first portion 610 of single layer 620 using separationdistance 634. In other embodiments, the separation distance may varyduring the step of printing the first portion of the single layer (notshown).

In some embodiments, a second portion of a single layer for thethree-dimensional structural component may be printed, as in step 310(see FIG. 3) onto the base so that the second portion has the secondthickness. Referring to FIG. 7, printing device 102 may dispense printmaterial 702 in a liquid state onto base 410. In the example, curingdevice 220 may emit ultraviolet light 704 onto base 410 to cure secondportion 720 of single layer 620. In other embodiments, the secondportion may be printed differently.

In some embodiments, the printing device may print the second portion ofthe single layer during the single pass. In some embodiments, printingthe second portion of the single layer may include dispensing printmaterial in a liquid state from the printhead assembly onto the baseduring the single pass. Referring to FIG. 7, printhead assembly 140 maydispense print material 702 in a liquid state from printhead assembly140 onto base 410 during single pass 630. In some embodiments, printingthe second portion of the single layer may include curing the secondportion of the single layer during the single pass. Referring to FIG. 7,printhead assembly 140 may emit ultraviolet light 704 onto base 410 tocure second portion 720 of single layer 620 during single pass 630. Inother embodiments, the printing device may print the second portion ofthe single layer using additional and/or fewer steps.

In some embodiments, the printing device may print an amount of printmaterial based on the set of predetermined thicknesses. Referring toFIGS. 6-7, printing device 102 may print first portion 610 to a shorterheight than second portion 720 by dispensing a smaller volume of printmaterial for first portion 610 than second portion 720. In the example,printing device 102 may dispense print material 602 to print firstportion 610, which has a smaller volume than print material 702, whichis used to print second portion 720. That is, a volume of a printmaterial printed for a portion of a layer may be selected to achieve aheight of the set of predetermined thicknesses. In other embodiments,the printing device may print different thicknesses of a single layerusing different methods.

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the second portion of the single layer. Referring to FIG. 7,printhead assembly 140 may dispense print material 702 using separationdistance 634 between upper surface 636 and printhead assembly 140. Inthe example, curing device 220 may emit ultraviolet light 704 onto base410 to cure second portion 720 of single layer 620 using separationdistance 634. In other embodiments, the separation distance may varyduring the step of printing the second portion of the single layer (notshown).

Generally, any suitable number of portions may be printed onto a base toachieve any suitable shape of the single layer for the three-dimensionalstructural component. In some embodiments, such shapes may have astepped surface (see FIG. 16). In some embodiments, such shapes may havea surface having a linear slope such as a constant increase or decreasein thickness for the three-dimensional structural component (see FIG.21). In some embodiments, such shapes may have a surface having anon-linear slope such as a gradually increasing or decreasing of a rateof change to a thickness (see FIG. 9).

In some embodiments, a third portion of a single layer for thethree-dimensional structural component may be optionally printed ontothe base so that the third portion has a third thickness of the set ofpredetermined thicknesses. Referring to FIG. 8, printing device 102 maydispense print material 802 in a liquid state onto base 410. In theexample, curing device 220 may emit ultraviolet light 804 onto base 410to cure third portion 830 of single layer 620. It should be understoodthat an additional or fewer number of portions of the single layer maybe used to form any suitable shape. In other embodiments, the thirdportion may be printed differently.

In some embodiments, the printing device may print the third portion ofthe single layer during the single pass. In some embodiments, printingthe third portion of the single layer may include dispensing printmaterial in a liquid state from the printhead assembly onto the baseduring the single pass. Referring to FIG. 8, printhead assembly 140 maydispense print material 802 in a liquid state from printhead assembly140 onto base 410 during single pass 630. In some embodiments, printingthe third portion of the single layer may include curing the thirdportion of the single layer during the single pass. Referring to FIG. 8,printhead assembly 140 may emit ultraviolet light 804 onto base 410 tocure third portion 830 of single layer 620 during single pass 630. Inother embodiments, the printing device may print the third portion ofthe single layer using additional and/or fewer steps.

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the third portion of the single layer. Referring to FIG. 8,printhead assembly 140 may dispense print material 802 using separationdistance 634 between upper surface 636 and printhead assembly 140. Inthe example, curing device 220 may emit ultraviolet light 804 onto base410 to cure third portion 830 of single layer 620 using separationdistance 634. In other embodiments, the separation distance may varyduring the step of printing the third portion of the single layer (notshown).

Generally, the various portions of the single layer may be printedhaving any suitable thickness. In some embodiments, the first thicknessis less than the second thickness. Referring to FIG. 9, first portion610 of single layer 620 may be printed onto base 410 so that firstportion 610 has first thickness 910. In the example, second portion 720of single layer 620 may be printed onto base 410 so that second portion720 has second thickness 920. In the example, first thickness 910 may beless than second thickness 920. In other instances, first thickness maybe greater than or equal to second thickness (not shown). Likewise,third portion 830 of single layer 620 may be printed onto base 410 sothat third portion 830 has third thickness 930. In the example, secondthickness 920 may be less than third thickness 930. In other instances,second thickness may be greater than or equal to third thickness (notshown).

In some embodiments, the various portions of a single layer may form anupper surface having a smoothly sloped geometry. As used herein, asmoothly sloped geometry may refer to any shape having a gradual changein shape. Such a gradual change may include linear changes and/ornon-linear changes. Referring to FIG. 9, first portion 610, secondportion 720, and third portion 830 may form upper surface 940 ofthree-dimensional structural component 902. In the example, uppersurface 940 may have a rounded shape. In other embodiments, portions ofa single layer may form an upper surface having a stepped geometry (seeFIG. 16).

Some embodiments may permit use of multiple layers to allow athree-dimensional structural component to have different shapes. In someembodiments, use of multiple layers may permit a three-dimensionalstructural component to have a thicker shape (see FIG. 16). In someembodiments, use of multiple layers may permit a three-dimensionalstructural component to have a smooth surface contour with a largechange in height (see FIG. 22).

FIG. 10 shows a block diagram of a process for printing athree-dimensional structural component onto a base, in accordance withan exemplary embodiment. The various steps of FIG. 10 may be discussedwith respect to FIGS. 11-16. In some embodiments, the steps of FIG. 10use CMYK printing. In some embodiments, the steps of FIG. 10 may use acontinuous printing path. In other cases, other methods, techniques,and/or processes may be used. In some embodiments, the steps of FIG. 10may be implemented using the system illustrated in FIG. 1. In othercases, other systems and/or devices may be used. It should be understoodthat additional and/or fewer steps may be used. The processesillustrated in FIGS. 11-16 are for illustrative purposes only.

In some embodiments, a base may be provided, as in step 1002 (see FIG.10), to receive a three-dimensional structural component having a set oflayers. Step 1002 may have one or more features of step 302. Forexample, the base may be provided manually and/or automatically. Inanother example, a human user may select an upper style to facilitate acustomization of an article. Referring to FIG. 11, base 1112 may beprovided for an upper of an article of footwear. In other embodiments,the providing of a base to receive a three-dimensional structuralcomponent having a set of layers may be provided differently from theproviding of the base to receive a three-dimensional structuralcomponent having a single layer.

In some embodiments, a set of predetermined thicknesses for athree-dimensional structural component may be provided, as in step 1004(see FIG. 10). In some embodiments, step 1004 may have one or morefeatures of step 304. For example, the set of predetermined thicknessesmay be provided by a human user and/or the set of predeterminedthicknesses may be automatically generated by a computing device.Referring to FIG. 11, set of predetermined thicknesses 1189 may includefirst thickness 1102 and second thickness 1104. As shown, firstthickness 1102 may be greater than second thickness 1104. In otherinstances, second thickness may be greater than first thickness (notshown). In some embodiments, the set of predetermined thicknesses mayoptionally include more than two thicknesses (not shown). In otherembodiments, the providing of the set of predetermined thicknesses toreceive a three-dimensional structural component having a set of layersmay be provided differently from the providing of the set ofpredetermined thicknesses to receive a three-dimensional structuralcomponent having a single layer.

In some embodiments, the printing device may be instructed, as in step1006 (see FIG. 10) to print a set of layers for the three-dimensionalstructural component using the set of predetermined thicknesses. In someembodiments, step 1006 may have one or more features of step 306. Forexample, the set of predetermined thicknesses may be converted to athree-dimensional printable file. In another example, the set ofpredetermined thicknesses may use a digital image or image file.Referring to FIG. 11, computing system 104 may transmit set ofpredetermined thicknesses 1189 to printing device 102, which may belocally connected to computing system 104 or may be remotely connectedto computing system 104 using network 106. In other embodiments,instructing the printing device to print a set of layers may bedifferent than instructing the printing device to print a single layer.

In some embodiments, the printing device may move the printhead assemblyalong a first continuous printing path to print the first layer.Generally, the first continuous printing path may start and conclude atany suitable position of the base. Referring to FIG. 12, firstcontinuous printing path 1274 may begin at starting point 1272 andconclude at ending point 1276. In the example, starting point 1272 maybe positioned at left edge 210 and top edge 214. In the example, endingpoint 1276 may be positioned at right edge 212 and bottom edge 216. Inother instances, the first continuous printing path may be positioneddifferently with the base.

In some embodiments, a first layer for the three-dimensional structuralcomponent may be printed, as in step 1008 (see FIG. 10) onto the baseusing the set of predetermined thicknesses. In some embodiments, step1008 may have one or more features of step 308. For example, theprinting device may move the printhead assembly in a single pass (e.g.,left edge to right edge) for printing different portions of the firstlayer. In another example, printing a portion of the first layer mayinclude dispensing print material in a liquid state from the printheadassembly onto the base during the single pass and curing the portion ofthe first layer during a single pass. In another example, the printingdevice may print an amount of print material based on the set ofpredetermined thicknesses. In another example, a separation distancebetween an upper surface of the base and the printhead assembly mayremain constant during the step of printing the first layer. Referringto FIG. 12, printhead assembly 140 may dispense print material 1252 in aliquid state from printhead assembly 140 onto base 1112 during firstcontinuous printing path 1274. In the example, curing device 220 mayemit ultraviolet light 1262 onto base 1112 to cure first portion 1210 offirst layer 1220 during first continuous printing path 1274. In theexample, printhead assembly 140 may dispense print material 1254 in aliquid state from printhead assembly 140 onto base 1112 during firstcontinuous printing path 1274. In the example, curing device 220 mayemit ultraviolet light 1264 onto base 1112 to cure second portion 1212of first layer 1220 during first continuous printing path 1274. In otherembodiments, printing the first layer of a set of layers may bedifferent than printing a single layer.

Some embodiments of the printing system can include provisions thatpermit printing directly onto the article. In some embodiments, thefirst layer may be printed directly onto the base. Referring to FIG. 12,first layer 1220 may be printed directly onto base 1112. In otherembodiments, the three-dimensional structural component may be firstprinted onto a release layer and then transferred onto the base (notshown).

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the first layer. Referring to FIG. 12, printing device 102may move printhead assembly 140 parallel to upper surface 1236 such thatseparation distance 1234 between upper surface 1236 and printheadassembly 140 remains constant during first continuous printing path1274. In other embodiments, the separation distance may vary during thestep of printing the first layer (not shown).

Some embodiments permit the first layer that may be printed to havedifferent thicknesses at various positions of the base according to theset of predetermined set of thicknesses. In some embodiments, the firstlayer may be printed to have the first thickness at a first position ofthe base. Referring to FIG. 13, first layer 1220 may have thickness 1312at first position 1302 that is equal to first thickness 1102 of set ofpredetermined thicknesses 1189 (see FIG. 11). In some embodiments, thefirst layer may be printed to have the second thickness at a secondposition of the base. In the example, first layer 1220 may havethickness 1314 at second position 1304 that is equal to second thickness1104 of set of predetermined thicknesses 1189 (see FIG. 11). It shouldbe understood that the various portions of the first layer may beprinted having any suitable thickness. In the example, thickness 1312may be greater than thickness 1314. In other embodiments, the thicknessat the first position may be less than or equal to the thickness at thesecond position (not shown).

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly during the step of printing thefirst layer may change after printing the first layer. Referring to FIG.14, printing device 102 may elevate printhead assembly 140 in adirection perpendicular to upper surface 1236 from separation distance1234 to separation distance 1436. In the example, separation distance1436 is between upper surface 1236 and printhead assembly 140. In otherembodiments, the separation distance may remain constant after the stepof printing the first layer (not shown).

In some embodiments, the printing device may move the printhead assemblyalong a second continuous printing path to print the second layer.Generally, the second continuous printing path may start and conclude atany suitable position of the base. Referring to FIG. 15, secondcontinuous printing path 1574 may begin at starting point 1572 andconclude at ending point 1576. In the example, starting point 1572 maybe positioned at right edge 212 and bottom edge 216. In the example,ending point 1576 may be positioned at left edge 210 and top edge 214.In other instances, the second continuous printing path may bepositioned differently with the base.

In some embodiments, a second layer for the three-dimensional structuralcomponent may be printed, as in step 1010 (see FIG. 10), onto the firstlayer using the set of predetermined thicknesses. In some embodiments,step 1010 may have one or more features of step 308. For example, theprinting device may move the printhead assembly in a single pass (e.g.,left edge to right edge) for printing different portions of the secondlayer. In another example, printing a portion of the second layer mayinclude dispensing print material in a liquid state from the printheadassembly during the second pass and curing the portion of the secondlayer during the second pass. In another example, the printing devicemay print an amount of print material based on the set of predeterminedthicknesses. In another example, a separation distance between an uppersurface of the base and the printhead assembly may remain constantduring the step of printing the second layer. Referring to FIG. 15,printhead assembly 140 may dispense print material 1552 in a liquidstate from printhead assembly 140 onto first layer 1220 during secondcontinuous printing path 1574. In the example, curing device 222 mayemit ultraviolet light 1562 onto first layer 1220 to cure second portion1512 of second layer 1520 during second continuous printing path 1574.In the example, printhead assembly 140 may dispense print material 1554in a liquid state from printhead assembly 140 onto first layer 1220during second continuous printing path 1574. In the example, curingdevice 222 may emit ultraviolet light 1564 onto first layer 1220 to curefirst portion 1510 of second layer 1520 during second continuousprinting path 1574. In other embodiments, the printing of a second layerof a set of layers may be different than the printing of a single layer.

Generally, the step of printing the second layer may be initiated at anysuitable time after printing the first layer. In some embodiments, thestep of printing the second layer may be initiated after printing thefirst layer. Referring to FIGS. 13 and 15, first portion 1210 of firstlayer 1220 may be cured before print material 1552 and/or print material1554 for second layer 1520 is dispensed. In the example, second portion1212 of first layer 1220 may be cured before print material 1552 and/orprint material 1554 for second layer 1520 is dispensed. In someembodiments, the step of printing the second layer may be initiatedafter the printhead assembly is moved the first continuous printing path(see FIG. 12). In some embodiments, the step of printing the secondlayer may be initiated after a separation distance between an uppersurface of the base and the printhead assembly is modified (see FIG.14).

In some embodiments, the separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the second layer. Referring to FIG. 15, printing device 102may move printhead assembly 140 parallel to upper surface 1536 such thatseparation distance 1534 between upper surface 1536 and printheadassembly 140 remains constant during second continuous printing path1574. In other embodiments, the separation distance may vary during thestep of printing the second layer (not shown).

In some embodiments, the first layer and the second layer may be printedto have a thickness at a position of the base that is equal to acorresponding thickness of the set of predetermined thicknesses.Referring to FIG. 16, first layer 1220 may be printed having thickness1312 at first position 1302 of base 1112 that is equal to firstthickness 1102 of set of predetermined thicknesses 1189 (see FIG. 11).In the example, second layer 1520 may be printed having thickness 1606at first position 1302 of base 1112 that is equal to first thickness1102 of set of predetermined thicknesses 1189 (see FIG. 11). Likewise,first layer 1220 may be printed having thickness 1314 at second position1304 of base 1112 that is equal to second thickness 1104 of set ofpredetermined thicknesses 1189 (see FIG. 11). In the example, secondlayer 1520 may be printed having thickness 1608 at second position 1304of base 1112 that is equal to second thickness 1104 of set ofpredetermined thicknesses 1189 (see FIG. 11). In other embodiments,different layers of the three-dimensional structure may be printed tohave different thicknesses.

In some embodiments, the printed set of layers of the three-dimensionalstructural component may have a combined thickness at a position of thebase that is less than the separation distance used to print the firstlayer. Referring to FIG. 16, first layer 1220 may be printed havingthickness 1314 at second position 1304 of base 1112. In the example,second layer 1520 may be printed having thickness 1608 at secondposition 1304 of base 1112. In the example, a combined thickness ofthickness 1314 and thickness 1608 may be less than separation distance1234 (see FIG. 12) used when printing the first layer 1220.

In some embodiments, the printed set of layers of the three-dimensionalstructural component may have a combined thickness at a position of thebase that is greater than the separation distance used to print thefirst layer. Referring to FIG. 16, first layer 1220 may be printedhaving thickness 1312 at first position 1302 of base 1112. In theexample, second layer 1520 may be printed having thickness 1606 at firstposition 1302 of base 1112. In the example, a combined thickness ofthickness 1312 and thickness 1606 may be greater than separationdistance 1234 (see FIG. 12).

In some embodiments, portions of the first layer may extend further fromthe base than portions of the second layer. Referring to FIG. 16, firstlayer 1220 at first position 1302 may extend away from base 1112 furtherthan second layer 1520 at second position 1304. In other embodiments,each portion of the second layer may extend further from the base thanthe first layer (not shown).

In some embodiments, the second layer may cover at least a portion of anupper surface of the first layer. Referring to FIG. 16, second layer1520 may completely cover upper surface 1616 of first layer 1220 atfirst position 1302. In the example, second layer 1520 may completelycover upper surface 1616 of first layer 1220 at second position 1304. Inother embodiments, portions of the first layer may remain exposed afterprinting the subsequent layers (not shown).

FIG. 17 shows a block diagram of a process for printing athree-dimensional structural component onto a base, in accordance withan exemplary embodiment. The various steps of FIG. 17 may be discussedwith respect to FIGS. 18-22. In some embodiments, the steps of FIG. 17use CMYK printing. In some embodiments, the steps of FIG. 17 may use acontinuous printing path. In other cases, other methods, techniques,and/or processes may be used. In some embodiments, the steps of FIG. 17may be implemented using the system illustrated in FIG. 1. In othercases, other systems and/or devices may be used. It should be understoodthat additional and/or fewer steps may be used. The processesillustrated in FIGS. 18-22 are for illustrative purposes only.

In some embodiments, a base may be provided, as in step 1702 (see FIG.17), to receive a three-dimensional structural component having a set oflayers. Step 1702 may have one or more features of step 302. Forexample, the base may be provided manually and/or automatically. Inanother example, a human user may select an upper style to facilitate acustomization of an article. Referring to FIG. 18, base 1812 may beprovided for an upper of an article of footwear. In other embodiments,the providing of a base to receive a three-dimensional structuralcomponent having a set of layers may be provided differently from theproviding of the base to receive a three-dimensional structuralcomponent having a single layer.

In some embodiments, a set of predetermined thicknesses for athree-dimensional structural component may be provided, as in step 1704(see FIG. 17). In some embodiments, step 1704 may have one or morefeatures of step 304. For example, the set of predetermined thicknessesmay be provided by a human user and/or the set of predeterminedthicknesses may be automatically generated by a computing device.Referring to FIG. 18, set of predetermined thicknesses 1889 may includefirst thickness 1802 and second thickness 1804. As shown, firstthickness 1802 may be less than second thickness 1804. In otherinstances, first thickness may be greater than second thickness (notshown). In some embodiments, the set of predetermined thicknesses mayoptionally include more than two thicknesses (not shown). In otherembodiments, the providing of the set of predetermined thicknesses toreceive a three-dimensional structural component having a set of layersmay be provided differently from the providing of the set ofpredetermined thicknesses to receive a three-dimensional structuralcomponent having a single layer.

In some embodiments, the printing device may be instructed, as in step1706 (see FIG. 17), to print a set of layers for the three-dimensionalstructural component using the set of predetermined thicknesses. In someembodiments, step 1706 may have one or more features of step 306. Forexample, the set of predetermined thicknesses may be converted to athree-dimensional printable file. In another example, the set ofpredetermined thicknesses may use a digital image or image file.Referring to FIG. 18, computing system 104 may transmit set ofpredetermined thicknesses 1889 to printing device 102, which may belocally connected to computing system 104 or may be remotely connectedto computing system 104 using network 106. In other embodiments,instructing the printing device to print a set of layers may bedifferent than instructing the printing device to print a single layer.

In some embodiments, a three-dimensional structural component isprinted, as in step 1708, onto the base using the set of predeterminedthicknesses. The three-dimensional structural component may be printedusing any suitable number of layers. Although FIGS. 19-22 show twolayers, it should be understood that more than two layers may be printedto form the three-dimensional structural component.

In some embodiments, a first layer for the three-dimensional structuralcomponent may be printed onto the base using the set of predeterminedthicknesses. In some embodiments, the printing of a first layer for athree-dimensional structural component having a smoothly sloped geometrymay have one or more features of the printing of a three-dimensionalstructural component having multiple layers. For example, the printingdevice may move the printhead assembly in a single pass (e.g., left edgeto right edge) for printing different portions of the first layer. Inanother example, the printing device may move the printhead assembly ina continuous printing path. In another example, printing a portion ofthe first layer may include dispensing print material in a liquid statefrom the printhead assembly onto the base during the single pass andcuring the portion of the first layer during the single pass. In anotherexample, the printing device may print an amount of print material basedon the set of predetermined thicknesses. In another example, aseparation distance between an upper surface of the base and theprinthead assembly may remain constant during the step of printing thefirst layer. Referring to FIG. 19, printhead assembly 140 may dispenseprint material 1952 in a liquid state from printhead assembly 140 ontobase 1812 during first continuous printing path 1974. In the example,curing device 220 may emit ultraviolet light 1962 onto base 1812 to curefirst portion 1910 of first layer 1920. In the example, printheadassembly 140 may dispense print material 1954 in a liquid state fromprinthead assembly 140 onto base 1812. In the example, curing device 220may emit ultraviolet light 1964 onto base 1812 to cure second portion1912 of first layer 1920. In other embodiments, the printing of a firstlayer of a set of layers may be different than the printing of a singlelayer.

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly may remain constant during the stepof printing the first layer. Referring to FIG. 19, printing device 102may move printhead assembly 140 parallel to upper surface 1936 of base1812 such that separation distance 1934 between upper surface 1936 andprinthead assembly 140 remains constant during first continuous printingpath 1974. In other embodiments, the separation distance may vary duringthe step of printing the first layer (not shown).

In some embodiments, a separation distance between an upper surface ofthe base and the printhead assembly during the step of printing thefirst layer may change after printing the first layer. Referring to FIG.20, printing device 102 may elevate printhead assembly 140 perpendicularto upper surface 1936 from separation distance 1934 between uppersurface 1936 of base 1812 and printhead assembly 140 to separationdistance 2036 between upper surface 1936 of base 1812 and printheadassembly 140. In other embodiments, the separation distance may remainconstant after the step of printing the first layer (not shown).

In some embodiments, a second layer for the three-dimensional structuralcomponent may be printed onto the base using the set of predeterminedthicknesses. In some embodiments, the printing of a second layer for athree-dimensional structural component having a smoothly sloped geometrymay have one or more features of the printing of a three-dimensionalstructural component having multiple layers. For example, the printingdevice may move the printhead assembly in a single pass (e.g., left edgeto right edge) for printing different portions of the second layer. Inanother example, the printing device may move the printhead assembly ina continuous printing path. In another example, printing a portion ofthe second layer may include dispensing print material in a liquid statefrom the printhead assembly during the continuous printing path andcuring the portion of the second layer during the continuous printingpath. In another example, the printing device may print an amount ofprint material based on the set of predetermined thicknesses. In anotherexample, a separation distance between an upper surface of the base andthe printhead assembly may remain constant during the step of printingthe second layer and/or during the continuous printing path. Referringto FIG. 21, printhead assembly 140 may dispense print material 2152 in aliquid state from printhead assembly 140 onto first layer 1920 duringsecond continuous printing path 2174. In the example, curing device 222may emit ultraviolet light 2162 onto first layer 1920 and/or base 1812to cure second layer 2120. In other embodiments, the printing of asecond layer of a set of layers may be different than the printing of asingle layer.

Generally, the printed set of layers may be considered as including anysuitable number of regions for printing a three-dimensional structuralcomponent to a desired shape. In some embodiments, the printed set oflayers may include a first region and a second region that are connectedby a transitioning region. Referring to FIG. 22, printed set of layers2202 may include exposed surface 2250 having intermediate region 2214abutting tall region 2212 on one side and abutting short region 2216 onthe other side. In other embodiments, the printed set of layers may beconsidered as having different regions or printing a three-dimensionalstructural component to a desired shape.

In some embodiments, the short region may have a thickness of less thanthe separation distance. Referring to FIG. 22, short region 2216 may beformed to have short height 2242. In the example, short height 2242 maybe less than separation distance 1934 used to print first layer 1920(see FIG. 19). In other embodiments, the short region may have athickness equal to or greater than the separation distance.

In some embodiments, a difference in height between the tall region andthe short region may be greater than the separation distance. Referringto FIG. 22, tall region 2212 may have tall height 2232. In the example,tall height 2232 may have a difference in height from short height 2242that is greater than separation distance 1934 used to print first layer1920 (see FIG. 19). In other embodiments, a difference in height betweenthe tall region and the short region may be equal to or less than theseparation distance.

Generally, the intermediate region may have any suitable shape. In someembodiments, the intermediate region may have a smoothly slopedgeometry. As used herein a smoothly sloped geometry may include anysuitable geometry that is free of any protrusions, projections, and/orindentations. Such protrusions, projections, and/or indentations mayinclude geometries that are stepped. In some embodiments, theintermediate region may be planar. In some embodiments, the intermediateregion may be contoured. As used herein, a region may be consideredcontoured when it has an irregular shape. Examples of an irregular shapemay include non-linear slopes, stepped surfaces, and the like. Referringto FIG. 22, intermediate region 2214 may have a contour that is a linearslope to form printed set of layers 2202 that has a triangular shape. Inother embodiments, the intermediate region may have other geometries.

Generally, the intermediate region may have any suitable slope tosmoothly transition between a short region and a tall region. In someembodiments, an angle formed between a plane parallel with theintermediate region of the exposed surface and a plane parallel with thebase may be between 15 and 75 degrees. Referring to FIG. 22, angle 2206may be formed between plane 2222 and plane 2224. In the example, plane2222 may be parallel with base 1812, and plane 2224 may be parallel withintermediate region 2214. In the example, angle 2206 may be 45 degrees.In other embodiments, the angle formed between a plane parallel with theintermediate region of the exposed surface and a plane parallel with thebase may be different.

Some embodiments can include provisions for increasing the precision ofprinting smooth contoured 3D surfaces. In some embodiments, a printingsystem can include provisions for correlating a spot color percentagefor a given ink with a desired ink layer height. Here, the term ‘spotcolor’ may refer to the use of a standardized ink or print material forwhich various properties (such as color density for a given quantity ofink) are known. In other words, a spot color may also be referred to asa standardized color. In the context discussed in the followingembodiment, ‘spot color’ can refer to clear structural inks as well. Insome cases, a known greyscale spot color range (0-100%) may be used fora clear structural ink. However, instead of using variations in spotcolor percentage to control color density in a layer, the print systemmay use spot color to control the thickness of one or more structurallayers.

FIG. 23 illustrates a schematic relationship between a clear (CLR) spotcolor percentage for a given clear structural ink (column 2302), and aresulting print layer thickness (column 2304). If provided with the datacontained in such a table, a print system can print layers of a widerange of thicknesses by selecting the associated spot color percentagefor printing to achieve the desired thickness (alternatively a designerand/or graphics program can provide data with the desired spot colorpercentages to a printing system to achieved desired thicknesses in theresulting printed object). This may allow for the creation of verysmooth contours and height gradients as the print system has very fineand precise control over layer thicknesses.

For example, FIGS. 24 and 25 illustrate two schematic views ofembodiments of printed structures with smoothly varying heights thathave been achieved by printing layers according to gradually varyingcolor percentages. In FIG. 24, printed object 2402 has a position 2403with a maximum height 2404 that corresponds with printing using a 100%spot color designated for the clear structural ink. A position 2405 justadjacent position 2403 has a height that is very slightly less thanmaximum height 2404 by printing using 99.5% spot color. In FIG. 25, aprinted object 2502 has a position 2503 with maximum height 2504 that istwice the maximum height 2404 of FIG. 24. To achieve this thickness, twolayers of 100% spot color are printed at position 2503.

In the embodiments of FIGS. 23-25, the corresponding print layerthicknesses are linear in the spot color percentage. In someapplications, depending on the type of ink used and/or other propertiesof the printing system, the print layer thickness may not be linear inthe spot color percentage. This may occur because the amount of inkrequired to linearly vary the color density (which determines the spotcolor percentages) may result in non-linear variations in height orthickness of printed ink layers. In order to allow a designer to createsmoothly varying contours that change in small and regular intervals(layer heights), it may be desirable to find a modified set of spotcolor percentage values that correspond with a set of regularly spacedthicknesses.

FIG. 26 illustrates a process for finding a modified (or ‘linearized’)set of spot color percentages that yield regularly spaced layerthicknesses. At least some of the following steps may be performed by anoperator of the printing system, or other system technician. In somecases, one or more of the steps can be performed by the printing systemand/or by a separate computing system.

In step 2602, an operator may print a range of spot color percentages todifferent regions of a substrate. For example, the operator could print20 spots of ink corresponding to regularly increasing spot colorpercentages (e.g., 5%, 10%, 15%, etc.). Next, in step 2604, the operatormay measure the thicknesses of each region containing ink applied usinga different spot color percentage. Exemplary tools and techniques formaking such precision measurements can include, but are not limited to:magnetic pull-off gauges, eddy current techniques, ultrasonic techniquesas well as other tools and techniques known in the art.

Next, in step 2606, the operator may compare the measured thicknesses tothe predetermined target thicknesses, for example using a spreadsheet.In some cases, the predetermined target thickness may be determinedaccording to the assumption that the thickness would vary linearly inheight as a function of spot color percentage. In step 2608, theoperator may generate a corrected table of spot color percentages forachieving the predetermined target thicknesses (e.g., using aspreadsheet).

Finally, in step 2610, the operator may make sure the corrected ormodified table is used during printing. In some embodiments, themodified table could be used on graphic data prior to sending it to theprinting system. For example, a graphics program that outputs graphicdata for use by the printing system may automatically select spot colorpercentages for printing using the modified table. In other embodiments,the modified spot color percentages could be incorporated into thesoftware of the printing system (e.g., as logic or as a look-up tablestored in a database).

FIG. 27 illustrates an example of a modified table that provides acorrelation between target thickness and an ‘adjusted spot colorpercentage’. In the left-most column 2702 of the table are regularintervals of the spot color percentage from 0 to 100 percent. In thenext two columns (column 2704 and column 2706) are the measured layerthickness and target (expected) thickness for those spot colorpercentages, respectively. Because the measured thicknesses and targetthicknesses are different the table includes a final column 2008 with anadjusted spot color percentage. It is the adjusted spot colorpercentages that should be used to achieve a desired target thickness inthe same row, rather than the spot color percentages in the first column2702. For example, using the table of FIG. 27, in order to print a layerwith a target thickness of 0.34 mm (from column 2706) the system shouldbe instructed to print a 15.1% spot color (from the same row in column2708).

Using the methods described herein a manufacturer can allow a designerto use spot color percentage to net a desired thickness and yield thedesired contour with a high level of accuracy. The contour transitionsthat employ spot color percentage may be smoother than contourtransitions that can be achieved by using conventional techniques, suchas a three-dimensional file slicing method used by conventionalthree-dimensional printer that result in topographical map style layerbuilds. This may be accomplished in an efficient manner by providingprint instructions in terms of percentages of known spot colors, forwhich a printing system, or other software, already has known data(i.e., the amount of ink or print material required to achieve a desiredpercentage for a given spot color). For example, a graphics programcould be configured to output grayscale images with given percentage ofa spot color at each pixel that will achieve a desired layer height in a3D object that corresponds with that pixel.

This spot color percentage may be used in conjunction with the othermethods described above to achieve a structural component with a smoothgradient when printing the structural component. Such a method ofprinting a three-dimensional structural component onto a base mayinclude receiving a set of target thicknesses for a three-dimensionalstructural component having printed regions. The spot color correlationmay be used to determine a thickness for each region of thethree-dimensional structural component. Each thickness in the set oftarget thicknesses may correspond to a different percentage of aselected spot color.

As discussed above, the set of target thicknesses may be provided by auser or calculated by a computer. Each printed region may be printedaccording to a different percentage of a selected spot color, as shownin FIG. 24. The target thickness for the printed region may becorrelated to the percentage of a selected spot color used for printingthe printed region, as shown in FIG. 27. The set of target thicknesseshas a first thickness and a second thickness. In some embodiments, thefirst thickness may be less than the second thickness.

A printing device such as printing device 201 may be used to print asingle layer for the three-dimensional structural component using theset of predetermined thicknesses. A printing device may print a firstregion of the single layer onto the base so that the first portion hasthe first thickness and a second region of the single layer onto thebase so that the second portion has the second thickness.

The printed thickness of each printed region may then be measured tocompare comparing the printed thickness of each printed region with thetarget thickness for the printed region. Finally, for each targetthickness, an adjusted percentage for the spot color required to print alayer of structural print material having the target thickness may bedetermined.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting, and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Any feature of any embodiment may be used in combinationwith or as a substitute for any other feature or element in any otherembodiment unless specifically restricted. Accordingly, the embodimentsare not to be restricted except in light of the attached claims andtheir equivalents. Also, various modifications and changes may be madewithin the scope of the attached claims.

The invention claimed is:
 1. A method of printing a three-dimensionalstructural component onto a base, the method comprising: receiving a setof predetermined thicknesses for the three-dimensional structuralcomponent; wherein the set of predetermined thicknesses has a firstthickness corresponding to a first position of the base and a secondthickness corresponding to a second position of the base, the firstthickness being greater than the second thickness; instructing aprinting device to print a set of layers of the three-dimensionalstructural component using the set of predetermined thicknesses, the setof layers comprising at least a first layer and a second layer; printingthe first layer of the three-dimensional structural component directlyonto the base using the set of predetermined thicknesses; whereinprinting the first layer includes printing the first layer to have thefirst thickness at the first position of the base and wherein printingthe first layer includes printing the first layer to have the secondthickness at the second position of the base; printing the second layerof the three-dimensional structural component directly onto the firstlayer using the set of predetermined thicknesses; wherein printing thesecond layer includes printing the second layer to have the firstthickness at the first position of the base and wherein printing thesecond layer includes printing the second layer to have the secondthickness at the second position of the base; wherein a separationdistance between the base and a printhead assembly of the printingdevice remains constant during the step of printing the first layer;wherein the set of layers of the three-dimensional structural componenthas a combined thickness at the second position of the base that is lessthan the separation distance; and wherein the set of layers of thethree-dimensional structural component has a combined thickness at thefirst position of the base that is greater than the separation distance.2. The method of claim 1, wherein printing the second layer is initiatedafter printing the first layer.
 3. The method of claim 2, whereinprinting the first layer comprises dispensing a print material in aliquid state onto the base and curing the print material such that thefirst layer has the first thickness at the first position of the baseand the first layer has the second thickness at the second position ofthe base; and wherein printing the second layer is initiated aftercuring the print material.
 4. The method of claim 1, wherein the firstlayer at the first position of the base extends away from the basefurther than the second layer at the second position of the base.
 5. Themethod of claim 1, wherein the second layer is printed directly onto afirst upper surface of the first layer; and wherein the second layercovers at least a portion of the first upper surface.